Instruction ManualSCPP 1 Circumferential Piston Pump

ESE01681-EN1 2010-04

Original manual

danieleCORRECT OMD LOGO

Table of contents

The information herein is correct at the time of issue but may be subject to change without prior notice

2. General description .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.1. General description .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. Safety .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.1. Important information ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.2. Recycling information ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.3. Safety precautions ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4. Installation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.1. Unpacking, Handling and Storage .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.2. Installation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.3. System design and installation ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.4. Startup checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5. Cleaning and maintenance ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.1. Cleaning and maintenance .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.2. Cleaning ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6. Maintenance ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146.1. Preventive maintenance ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146.2. Annual maintenance .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

7. Disassembly and assembly .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167.1. Pump head and seal assembly and disassembly .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167.2. Gear box disassembly and assembly .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8. Operation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238.1. Troubleshooting guide .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3

.

4

EC Declaration of Conformity

The designating company

Alfa Laval Eastbourne, Alfa Laval LtdCompany Name

Birch Road, Eastbourne, East Sussex BN23 6PQAddress

+44 (0) 1323 412555Phone No.

hereby declares that:

- Circumferential piston pumps within “SCPP” range

from serial number 150000 are in conformity with the provisions of the Machinery Directive 2006/42/EC and with thenational implementing legalization and EC regulation 1935/2004 relating to materials and articles intended to come intocontact with food

and furthermore declares that:

If motorised the following (parts/clauses of) applicable directives have been used- Directive 2006/95/EC on low voltage- Electro Magnetic Compatibility Directive 2004/108/EC

The technical construction file for this machinery is retained at the above address.

Signed Date(Authorised Person)

Name Bjarne Søndergaard Position Vice President R&D Equipment Division

5

2 General description

To ensure the best possible service, read and understand this manual prior to installation, operation or maintaining this pump.For questions regarding installation, operation or maintenance, contact your distributor or Alfa Laval

2.1 General description

Each Pump product is shipped completely assembled and ready for use. Normal maintenance as outlined in this manual willprovide long, trouble free service when the pumps is incorporated in a properly designed system.

Inspection at receipt: ports are covered at the factory to prevent dirt and foreign objects from entering the pump head. If portcovers are damaged or missing remove the pump cover to ensure the pump is clean and free of foreign objects or materialsbefore rotating the shaft. If the pump is damaged in transit file a claim with the carrier right away. The carrier has a Bill of Ladingshowing that the shipment was received from us in good condition.

Returns: when necessary to return product under warranty or for any other reason first contact Alfa Laval to receive a ReturnGoods Authorization number to facilitate getting the product back to you as soon as possible.

Normal operationNormal operation of the Pump products is within a range of 0 to 600 rpm, and a pressure range of 0 to 1379 kPa (0 to 200 psi).Standard rotors operate within a temperature range of -40°C to 93°C (-40°F to 200°F). Hot clearance rotors operate at 93°C to149°C (200°F to 300°F). Consult factory for operation at other values.

Noise LevelsUnder certain operating conditions pumps and/or drives and/or the systems within which they are installed can produce soundpressure levels in excess of 80dB[A]. When necessary, protection against noise should be taken.

Weight for bare shaft pump

Model006 015 018 030 045 060 130 220 320

Weight kg 24 24 24 45 132 132 142 252 477Weight lb 53 53 53 99 290 290 312 555 1050

Typical weight for motor and baseplates

kW0.37 0.55 0.75 1.10 1.50 2.20 3.00 4.00 5.50 7.50 11.00 15.00

Weight kg 42 45 49 60 64 81 91 114 157 200 293 387Weight lb 93 99 108 132 141 179 201 251 346 441 646 853

6

3 Safety

Incorrect installation, operation or maintenance of equipment may cause severe personal injury or death and/or equipmentdamage and may invalidate the warranty. This information must be read fully before beginning installation, operation ormaintenance and must be kept with the pump. All installation and maintenance must be undertaken by suitably trainedor qualified persons only.

3.1 Important information

Safety instructions are identified in this manual with the symbol

Where electrical safety is involved with the symbol

The symbol Attention is used to call attention to instructions important to protection of equipment. ATTENTION

WARNING:Hazards or unsafe practices that could result in severe personal injury or death, and how to avoid them.

CAUTION:Hazards or unsafe practices that could result in minor personal injury or damage to product or property.

WARNING ! To avoid serious injury or death, do not install or service pump unless power is off and locked out.

WARNING ! WARNING ! Before servicing pump, refer to Material Safety Data Sheet (MSDS) for safe handling of the materialbeing pumped.

WARNING ! Do not operate pump without guards in place.

WARNING ! Stay clear of motor shaft and coupling when jogging motor.

WARNING ! Do not operate pump under power with cover removed.

CAUTION ! Handle all parts with care to avoid nicks and scratches which may affect pump operation.

CAUTION ! Pump components have very close clearances. Do not permit foreign objects to enter the pump.

WARNING ! Electrical connections must be made by a registered electrician in accordance with local codes and standards.

WARNING ! Do not operate pump unless over- pressure protection is installed in discharge piping.

WARNING ! Do not put fingers in ports or near rotating members.

WARNING ! Relieve system pressure before removing cover or port connections.

CAUTION ! Operation of the pump with inlet and/or outlet valves in the closed position can cause damage to the pump.

CAUTION ! Before operating pump under power, make sure system is clean and free of foreign objects. Do not use pump toremove foreign objects.

7

3 Safety

3.2 Recycling information

Recycling information.• Unpacking

- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.- Wood and cardboard boxes can be reused, recycled or used for energy recovery.- Plastics should be recycled or burnt at a licensed waste incineration plant.- Metal straps should be sent for material recycling.

• Maintenance

- During maintenance oil and wear parts in the machine are replaced.- All metal parts should be sent for material recycling.- Worn out or defective electronic parts should be sent to a licensed handler for material recycling.- Oil and all non metal wear parts must be taken care of in agreement with local regulations.

• Scrapping

- At end of use, the equipment shall be recycled according to relevant, local regulations. Beside the equipment itself, anyhazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in theabsence of local regulations, please contact the local Alfa Laval sales company.

3.3 Safety precautions

Section installation.

Some pump configurations could tip if inclined at a 10° angle or more. Ensure lifting equipment is used or pump is supportedbefore unbolting from base plates, packaging or other.

Section Operation.

Under certain conditions surface temperatures on the gear box could be in excess of 80°C and caution must be taken.

Section Maintenance.

Hazardous fluid could be trapped in some rotorcase orientations and/or seal housings and caution must be taken. Whendisposing of harmful substances or substances above 60°C please be aware that in some orientations the rotor case and/orseal housings are not fully drainable. If requested at the time of order the equipment can be supplied with means of saferemoval of any hazardous and/or hot , drained or leaked fluid.

Always secure that the pump can not turbine due to backflow caused by discharge head in the system.

8

4 Installation

4.1 Unpacking, Handling and Storage

Step 1

Refer to the pump weights guide (8.1 Troubleshooting guide) before selecting and using any lifting gear. The drawingsshow how the pump should be lifted.Ensure that lifting equipment is correctly rated and used within these limits.

Pump with drive unit Bareshaft pump

4.2 Installation

Consideration must be given to the following in order to achieve proper installation

Step 1Pumps of this type are usually mounted on a base plate common with the drive unit. Bases may be permanently mounted, beself-leveling and with vibration isolation pads, have adjustable legs or be portable. Bases should be level during pump operation.

Step 2Provide power as required by the motor and controls as needed for system operation.

WARNING !Electrical connections must be made by a registered electrician in accordance with local codes and standards.

WARNING !To avoid serious injury or death, do not install or service pump unless power is off and locked out.

Step 3Piping should be supported independently of the pump to prevent mis-alignment of pump parts that will cause excessive wear torotors, bearings and shafts. Use of thermal expansion (flexible) joints will also minimize forces exerted on the pump. Inlet andoutlet valves permit servicing of the pump without emptying the entire system. Inlet piping must not slope toward the pump insuch a way as to cause formation of an air pocket ahead of the pump. An inlet valve will serve to keep the inlet line full. This isparticularly important with low viscosity fluids and with frequent starts and stops. With low absolute inlet pressure a check on theoutlet side of the pump prevents backflow and minimizes start-up differential pressure.

CAUTIONOperation of the pump with inlet and/or outlet valves in the closed position can cause damage to the pump.

Step 4Welding of fittings is not recommended since warpage can occur which may affect pump operation and performance.

Step 5Overpressure protection must be provided for this pump. An external/bypass pressure relief valve, a torque limiting deviceon the drive or a rupture disc in the discharge piping are examples. If pump rotation is to be reversed, pressure protectionmust be provided on both sides of the pump.

WARNING !Do not operate pump unless over- pressure protection is installed in discharge piping.

9

4 Installation

Installation should follow good practice to provide the best performance and installation must meet local code requirements. Allsystem components must be correctly sized to provide satisfactory operation of your Alfa Laval product.

Step 6Inlet side strainers or traps can be used to prevent foreign objects from entering and damaging the pump. Selection should bemade based on viscosity to prevent clogging and restricting the inlet thus causing cavitation and reduction of flow from the pump.

Step 7Installation of pressure and/or vacuum gauges at inlet and/or outlet provide a convenient way to assess pump operation. Suchgauges can indicate if pressure is normal or not, show changes in pump or system conditions, and provide indications offlow and changes in viscosity.

Step 8Pumps and drives ordered from the factory on a common baseplate have been supplied with a flexible coupling and alignedbefore shipping. This alignment should be rechecked after thepump is installed and piping is complete.Using feeler gages check angular alignment in four places aroundthe coupling. The alignment and space between the couplingsshould be set to the manufacturer’s recommended distance. Shimas needed. Refer to Figure 2.Using a straight edge check parallel alignment as shown in Figure3. Shim height as needed.

Shim as

TD 249-039

needed

figure 2

Straight edge

Shim asTD 249-040

required

figure 3

Step 9Turn shaft manually to make sure that the pump turns freely.

WARNING !Do not put fingers in ports or near rotating members.

Step 10Jog motor and observe motor coupling to make sure pump willturn in the right direction. Refer to Figure 4.

WARNING !Stay clear of motor shaft and coupling when jogging motor.

TD 249-026

Top Shaft Drive

TD 249-027

Bottom Shaft Drivefigure 4

Step 11Lock out power to pump.

WARNING !To avoid serious injury or death, do not install or service pumpunless power is off and locked out.

10

4 Installation

Installation should follow good practice to provide the best performance and installation must meet local code requirements. Allsystem components must be correctly sized to provide satisfactory operation of your Alfa Laval product.

Step 12Connect coupling halves and install coupling guard.

WARNING !Do not operate pump without guards in place.

WARNING !Do not put fingers in ports or near rotating members.

Step 13Make sure inlet and outlet connections are tightened. If pump hasdouble seals connect seal flushing piping. These connectionsare normally 3.18 mm (1/8”) female pipe threads. Liquid usedfor flushing is thereby connected to the seals and discharged todrain on the opposite side. Flow should be about 0.92 M3/hr (1/4GPM), but may be increased for high temperature applications,but should be kept as near to 0.92 M3/hr (1/4 GPM) as possible toavoid seal damage.

Inlet Outlet

InletTD 249-103

Outlet

Step 14Lubrication

Gears are lubricated with Micro-Plate #140 oil for top or bottom shaft mounting position and oil is added at the factory.Oil Capacity

Model Top or Bottom Shaft Mount Side Mount006 1.3 oz (40 ml) 3.3 oz (100 ml)015 1.3 oz (40 ml) 3.3 oz (100 ml)030 2.0 oz (60 ml) 4.0 oz (120 ml)045 6.0 oz (170 ml) 9.5 oz (280 ml)060 6.0 oz (170 ml) 9.5 oz (280 ml)130 6.0 oz (170 ml) 9.5 oz (280 ml)220 11.0 oz (320 ml) 20.0 oz (600 ml)

table 1Bearings are greased with Micro-Plate Moly grease. Grease bearings after every 250 hours of operation; change oil every 500hours. Where moisture and/or condensation are heavy change oil and grease more frequently. If temperature is -15°C (5°F)or below, bearings should be greased with silicon grease.

11

4 Installation

4.3 System design and installation

Pipework:All pipework must be supported. The pump must not be allowed to support any of the pipework weight beyond the limitsset as shown in the following table.

Remember:Pipework supports must also support the weight of the productbeing pumped.- Design short straight suction lines to reduce friction losses

in the pipework thereby improving the NPSH available fromthe system.

- Avoid bends, tees and any restrictions close to eithersuction or discharge side of pump. Use long radius bendswherever possible.

- Provide isolating valves on each side of the pump whennecessary.

- Keep pipework horizontal where applicable to reduce airlocks. Include eccentric reducers on suction lines.

TD 249-104

X

Y

Z

Table of Maximum Forces and MomentsPipe dia. F(x, y or z) F(total) M(x, y or z) M(total)

(mm) max. (N) max. (N) max. (Nm) max. (Nm)25 190 270 85 12540 255 360 115 17050 295 420 145 21080 425 600 215 315

100 505 720 260 385125 610 870 325 480150 720 1020 385 565

4.4 Startup checklist

- Has protection from high pressure been considered? See page 9.- Are pump and all piping clean and free of foreign material, gaskets, weld slag, bolts etc.? Do not use pump to clean system.- Are connections tightened and leak free?- Is gear drive properly lubricated? See item 14 above.- Are all guards in place and secure?- Have seals requiring flushing been supplied with an adequate supply of clean flushing fluid?- Are all valves open on the discharge side of the pump?- Are all valves open on the inlet side of the pump, and is the material to be pumped reaching the pump?- Is direction of rotation correct? See item 10 above.- Jog or start pump at low speed when possible.

Check to see that pump is performing properly within several minutes. If problems are detected, see Troubleshooting Guideon page 23.

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5 Cleaning and maintenance

5.1 Cleaning and maintenance

Pump products are designed for easy removal of the cover, rotors and seals for cleaning when necessary. Disassembly andassembly of the pump head and seals starts on page 16.

WARNING !To avoid serious injury or death, do not install or service pump unless power is off and locked out.

WARNING !Relieve system pressure before removing cover or port connections.

CAUTION ATTENTION

Handle all parts with care to avoid nicks and scratches which may affect pump operation.

WARNING !Installation and operation of the pump must always comply with health and safety regulations. Any hazardous and/or hotdrained, or leaked liquid shall be disposed of in compliance with health and safety regulations.If requested at the time of order, the equipment can be supplied with means of safe removal of any hazardous and/or hot,drained or leaked fluid.

5.2 Cleaning

Clean per established procedures. Be aware of the cleaning solution used (see MSDS), and of cleaning solution temperature.Make sure no residual cleaning solution stays in the pump.

Note that acidic cleaners have a high metal corrosion rate, so pump parts should be exposed to these cleaners no longer thannecessary and be completely rinsed.

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6 Maintenance

6.1 Preventive maintenance

Simple inspection during cleaning will often detect signs of a problem before it becomes serious so that it can be corrected atminimal cost and down-time.

Remove rotors. Use rotor nut wrench and soft faced hammer. Visually inspect rotor wing tips for signs of metal-to-metalcontact. If present the pump should be repaired or replaced.

Possible causes:Worn shaft keyway replace shaft.Worn rotor keyway replace rotor (usually both parts wear,

often due to running a loose rotor).Loose or worn gears, key, keyway shaft inspect and replace as needed.

Visually inspect the rotor hub where it contacts the shoulder on the shaft for wear.Possible cause:Running loose rotor replace rotor and correctly tighten or re-shim shaft to maintain

back-face clearance.

Inspect shoulder on shaft for wear.Possible cause:Running loose rotor replace or re-shim shaft.

Check gear backlash. Replace nuts and turn shaft with wrench. There should be no free movement ofeither shaft.

Possible causes:Worn gear teeth replace gearGear loose on shaft remove gear, inspect key, keyways and shaft. Replace worn

parts and retighten.

Check condition of bearings. Hand load (about 30 lbs.) each shaft. There should be no detectablemovement.

Cause of movement:Bearings worn due to lack of lubrication or overload replace bearings and ensure adequate lubrication, reduce

hydraulic load.

If gear box disassembly is required see instructions starting on page 19.See page 19 for rotor installation. When pump is assembled, there must be equal clearance as shown in Figure 5.

Follow lubrication intervals as shown on page 11.

Clearance on bothsides must be equal

TD 249-041

figure 5

14

6 Maintenance

6.2 Annual maintenance

Conduct the same checks as above, and in addition do the following:

Step 1Check bearings for radial play using a dial indicator as shown. If indicator reading is equal or greater than the rotor-to-bodyclearance in the table on page 21, replace bearings. Refer to Figure 6.

Step 2Drain oil, remove gear box cover and inspect gears for wear, backlash, and looseness. Retighten as needed.

Step 3Carefully inspect rotors visually for worn splines, bearing shoulder wear, and for stress cracks. Replace worn or crackedrotors. Refer to Figure 7.

Step 4Refer to Reference Table on page 21 and check radial and back face clearance to determine wear.

TD 249-029

TD 249-030

Inspect for stress cracks-

figure 6 figure 7

See instructions under Pump Head and Seal Assembly and Disassembly below for disassembly and assembly. When replacingbearings or shafts in the field care must be taken to properly shim the shaft to provide the correct clearances betweenthe rotors, body and cover.

Operating speed adjustment can compensate for wear in some applications. When performance is no longer acceptable youmay take advantage of the Alfa Laval remanufacturing plan, as follows.

Remanufacturing program:

This series of Alfa Laval pumps may be remanufactured up to four times depending on use and wear. Remanufactured pumpsare backed with the same warranty as a new pump. Factory remanufacturing involves body and cover remachining, new rotors,and replacement of all worn parts such as shafts, bearings, gears etc.

To facilitate the remanufacturing process contact the factory to discuss the particular pump(s) to be remanufactured and obtainreturn goods authorization. It may be possible to supply a remanufactured pump in advance of returning a pump to the factoryalthough not all sizes may be available at any one time. Be sure to clean and flush pump before returning it to the factory.

Apply gear, puller here.

Body O-ring

TD 249-042

Shaft O-ringTD 249-043

figure 8 figure 9

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7 Disassembly and assembly

7.1 Pump head and seal assembly and disassembly

Before disassembly, lock out power and release pressure from pump

WARNING !To avoid serious injury or death, do not install or service pump unless power is off and locked out.

WARNING !Relieve system pressure before removing cover or port connections.

CAUTION ATTENTION

Handle all parts with care to avoid nicks and scratches which may affect pump operation.

Step 1Pump head disassemblyRemove wing nuts using a soft hammer. Remove cover.If necessary, tap cover with soft hammer to loosen. Remove and discard cover O-ring.Use wrench supplied to remove rotor nuts. Nuts remove in a counter clock-wise direction. Hit wrench sharply with softhammer to loosen nuts.Orient rotors perpendicular to each other, then remove rotor with both wings exposed first. If necessary use gear puller orhardwood lever to remove rotor from spline.If fitted with Allen head hold down bolts in the body remove them, then remove pump body by pulling it straight off studs. Notethat the pump body must be assembled to the same bearing housing from which it was removed.

Step 2Seal disassembly

Single O-ringRemove and discard body and shaft O-rings. Use O-ring removal tool furnished with pump.

Double O-RingRemove O-ring carriers; remove and discard rings from both carriers and body. Use O-ring removal tool furnished.

Single Mechanical SealInner seal:Remove seal from body. If chipped, scratched or evidence of cracks, discard seal. Make sure shoulder is clean;remove burrs if present; remove and discard O-rings.

Seal seat:Remove seal seat from shaft. If chipped, scratched or evidence of cracks, discard seal. Make sure shoulder is clean;remove burrs if present; remove and discard O-rings.

Seal OuterO-ring

Carrie seat Seal seatbody Body Body Body

O-rings O-ring O-ring O-ring

Shaft Shaft O-ring

O-ringSleeve Shaft Inner Inner seal

O-ring seal Outer seal WavespringTD 249-044 TD 249-045 TD 249-046

16

7 Disassembly and assembly

Double Mechanical SealInner Seal:Remove seal from body. If chipped, scratched or evidence of cracks, discard seal. Make sure shoulder is clean;remove burrs if present; remove and discard O-rings.

Seal Seat:Remove seal seat from shaft. If chipped, scratched or evidence of cracks, discard seal. Make sure shoulder is clean;remove burrs if present; remove and discard O-rings.

Outer Seal:Remove seal from body. If chipped, scratched or evidence of cracks, discard seal. Remove and discard O-rings.

Step 3Seal AssemblyPrior to reassembling the pump head inspect all parts to make sure they are free from damage. Nicks, scratches and cracks inmechanical seal components may cause seal leakage, and nicks, scratches and burrs on any pump part may cause leakage orperformance problems. Refer to sketches with disassembly instructions.

Single O-ringApply a suitable O-ring lubricant to new O-rings and insert them into the body and shaft grooves. O-rings on shaftsshould be installed in the groove closest to the spline.Assemble shaft sleeves against shaft shoulder. If sleeve is slotted, assemble with slot over drive pin in shaft. If sleeve hasprongs assemble with prongs on either side of drive pin.

Double O-ringApply a suitable O-ring lubricant to new O-rings and insert them into the body, carrier and shaft grooves. O-rings onshafts should be installed in the groove closest to the spline when using O-ring seats. Assemble carriers into body socarrier notch engages pin in body.Assemble shaft sleeves against shaft shoulder. If sleeve is slotted, assemble with slot over drive pin in shaft. If sleeve hasprongs assemble with prongs on either side of drive pin.

Single Mechanical SealSeal Seat:Apply a suitable O-ring lubricant to new O-rings and insert them into shaft grooves furthest from spline.Install seal seats lining up groove on rear face with shaft drive pin.

Inner Seal:Apply a suitable O-ring lubricant to new O-rings and insert them into body grooves.Assemble wave spring on seal and install into body with notch engaging pin in body.Lubricate seal faces.

Double Mechanical SealSeal Seat:Apply a suitable O-ring lubricant to new O-ring and insert into shaft groove furthest from spline.Install seal seat lining up groove on rear face with shaft drive pin.

Inner Seal:Apply a suitable O-ring lubricant to new O-ring and insert into body groove.Assemble wave spring on seal and install into body with notch engaging pin in body.

Outer Seal:Apply a suitable O-ring lubricant to new O-rings and install on outer diameter of seal.Insert seal assembly into body engaging notch with pin and pushing from opposite side, over and in, to seat O-ring.Apply lubricant to seal faces.

17

7 Disassembly and assembly

Step 4Pump head assemblySlide body over shafts and studs taking care not to damage seal parts. Press body firmly against gear case engaging dowels.Install Allen Head bolts, where furnished.Assemble rotor to its shaft engaging the large spline tooth with large groove in rotor. Rotate shaft until rotor wings are on avertical centerline, then install second rotor. Secure with rotor retaining nuts: tighten first nut on shaft by striking nut wrench withsoft faced hammer, then tighten second nut against first in the same way to jam nuts together.Place cover O-ring in groove, push cover over studs making sure O-ring remains in groove.Attach wing nuts and tighten by striking with a soft hammer.Sterilize pump in accordance with accepted sterilization procedures. Make sure no residual solution remains in the pump.

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7 Disassembly and assembly

7.2 Gear box disassembly and assembly

Gear box disassemblyStep 1Remove pump head as shown starting on page 16 and drain oil from gear box.

Step 2Remove cap screws. Remove cover using soft hammer to loosen.

Step 3Scrape sealant from gear box and cover.

Step 4Remove oil seal from cover using an arbor press. Discard seal.

Step 5Using hammer and drift pin straighten locking tab on lock washers.

Step 6Prevent shafts from turning by wedging a wooden block between the gears.

Step 7Use a spanner wrench or drift pin to remove the gear lock nuts.

Step 8Wrap splines and ends of shafts with tape to protect them.

Step 9Remove front bearing retainer bolts and retainers. Remove sealant from retainers and gear box. (Retainer will press outwhen shaft is removed if it is stuck in place.)

Step 10Place gear box on arbor press with pump head end down. Protect shaft ends with a wooden block and press shafts outof gear box.

Step 11Remove sealant from bearing retainers, press out and discard grease seals.

Step 12Remove shims. If they will be reused identify the shaft on which they were used. Press out and discard rear grease seals.Refer to Figure 9.

Step 13Use hydraulic press and V blocks to remove bearings and spacer.

19

7 Disassembly and assembly

Gear box assemblyStep 1Coat front bearing area of shaft with Micro-Plate grease and position shaft in hydraulic press with spline down.

Step 2Place front bearing over shaft with shield side up. Press onto shaft until bearing is seated against shoulder. Place bearing spacerover shaft to seat on front bearing.

Step 3Coat rear bearing area on shaft with Micro-Plate grease. Slide rear bearing over shaft with shield side down. Press bearing ontoshaft until it seats against spacer.

Press againstPress against Rear bearing inner race only

Front bearing inner race only

Bearing spacer

TD 249-047

TD 249-048

figure 15 figure 16

Step 4The pumps have close running tolerances to provide efficient operation. The position of the rotors is controlled by the use ofshims behind the front bearing in the gear box . These shims control both the backface clearance between the rotors andthe bottom of the rotor pocket in the housing and the clearance between the rotors and the cover. See page 21 for thesedimensions. Clearance for both rotors should be equal to avoid rotor-to-rotor contact. To establish the correct shim thickness,make the following measurements in 0.025 mm (0.001 inches):A. Measure body width.B. Measure depth of rotor bore.C. Measure distance from gear box face to bottom of front bearing pocket in gear box.D. Slide rotor onto shaft and measure from back of rotor to back of front bearing.

Do calculations for shim thickness:

A – B = XC + X = Y(Y – D) + required backface clearance (from Reference Table, page 21) = shim thickness.

Repeat measurements for second rotor.

Step 5Place shim stock in the required thickness against shoulder in the bearing bore.

Step 6Place gearbox on arbor press with front (pump) end up. Place shaft assemblies in gear box with spline end up and with shafts inthe correct location to provide top or bottom drive as required. Press shafts into housing until bearing is seated against shims.

Step 7Place body on gear box, making sure it is firmly seated. Install rotors on shafts. Secure with rotor retaining nuts: tighten first nuton shaft by striking nut wrench with soft faced hammer, then tighten second nut against first in the same way to jam nuts together.Check back face clearance against value on page 21. If necessary remove rotors, then remove shafts to adjust shim thickness.

20

7 Disassembly and assembly

Step 8When back face clearance has been established in accordance with the value shown on page 21, remove body and secure shaftassemblies in the gear box with bearing retainers. Do not apply sealant at this time. Retainers must seat firmly against thebearing and leave 1.27-1.52 mm (0.050-0.060”) clearance between retainer and gear box.Use shims if needed to obtain this clearance. Refer to Figure 12.

1.27-1.52 mm Silicone sealant Seal(0.050-0.060”) clearance

Shim here if neededTD 249-036

TD 249-035

Coat with micro-plate #555

figure 12 figure 13

Step 9Make sure backface clearance is correct. Remove bearing retainers and grease both front and rear bearings through greasefittings until grease is visible around ball assemblies.

Step 10Install grease seals in bearing retainers. Coat seal lips with Micro-Plate #555 grease. Coat retainer flanges with silicone sealant.Install retainers. Refer to Figure 13.

Step 11Install rear oil seals and rear gear spacers.

Step 12Please keys into shaft key slots. Slide gear with single punch mark onto drive shaft. Slide gear with two punch marks ontoshort shaft, with punch marks aligned on each side of single mark on drive gear.

Step 13Install lock washers and lock nuts onto shafts. Tighten locknut with spanner wrench. Bend locking tab on lockwasher to secure.

Step 14Press in rear seal with lip facing inward. Refer to Figure 14.

Step 15Place silicone sealant on back of gear case and mount cover assembly on case.

Step 16Fill gear case with oil as specified on page 11.

Seal lip faces in

TD 249-037

figure 14

21

7 Disassembly and assembly

Reference table

Standard ClearancesBack face Rotor to body Front faceModel

application mm in mm in mm in006 0.038/0.051 0.0015 / 0.0020 0.051/0.076 0.0020 / 0.0030 0.102/0.152 0.0040 / 0.0060015 0.038/0.051 0.0015 / 0.0020 0.051/0.076 0.0020 / 0.0030 0.089/0.152 0.0035 / 0.0060

018 & 024 0.038/0.051 0.0015 / 0.0020 0.051/0.076 0.0020 / 0.0030 0.102/0.118 0.0040 / 0.0065030 & 034 0.051/0.064 0.0020 / 0.0025 0.0584/0.097 0.0023 / 0.0038 0.089/0.152 0.0035 / 0.0060060 & 064 0.076/0.089 0.0030 / 0.0035 0.097/0.145 0.0038 / 0.0057 0.139/0.229 0.0055 / 0.0090130 & 134 0.076/0.089 0.0030 / 0.0035 0.109/0.160 0.0043 / 0.0063 0.127/0.191 0.0050 / 0.0075220 & 224 0.102/0.127 0.0040 / 0.0050 0.114/0.118 0.0045 / 0.0065 0.127/0.191 0.0050 / 0.0090

Standard ClearancesModel

application Back face Rotor to body Front facemm in mm in mm in

006 0.038/0.051 0.0015 / 0.0020 0.084/0.076 0.0033 / 0.0030 0.102/0.152 0.0040 / 0.0060015 0.038/0.051 0.0015 / 0.0020 0.091/0.076 0.0036 / 0.0030 0.089/0.152 0.0035 / 0.0060

018 & 024 0.038/0.051 0.0015 / 0.0020 0.086/0.076 0.0034 / 0.0030 0.102/0.118 0.0040 / 0.0065030 & 034 0.051/0.064 0.0020 / 0.0025 0.102/0.097 0.0040 / 0.0038 0.089/0.152 0.0035 / 0.0060060 & 064 0.076/0.089 0.0030 / 0.0035 0.160/0.145 0.0063 / 0.0057 0.139/0.229 0.0055 / 0.0090130 & 134 0.076/0.089 0.0030 / 0.0035 0.173/0.160 0.0068 / 0.0063 0.127/0.191 0.0050 / 0.0075220 & 224 0.102/0.127 0.0040 / 0.0050 0.201/0.118 0.0079 / 0.0065 0.127/0.191 0.0050 / 0.0090

Standard ClearancesModel

application Back face Rotor to body Front facemm in mm in mm in

006 0.089/0.051 0.0035 / 0.0020 0.127/0.152 0.0050 / 0.0060 0.178/0.241 0.0070 / 0.0095015 0.114/0.051 0.0045 / 0.0020 0.127/0.152 0.0050 / 0.0060 0.165/0.254 0.0065 / 0.0100

018 & 024 0.114/0.051 0.0045 / 0.0020 0.109/0.132 0.0043 / 0.0052 0.191/0.279 0.0075 / 0.0110030 & 034 0.127/0.064 0.0050 / 0.0025 0.109/0.145 0.0043 / 0.0057 0.178/0.267 0.0070 / 0.0105060 & 064 0.152/0.089 0.0060 / 0.0035 0.191/0.241 0.0075 / 0.0095 0.254/0.356 0.0100 / 0.0140

130 & 134 0.152/0.089 0.0060 / 0.0035 0.191/0.241 0.0075 / 0.0095 0.254/0.356 0.0100 / 0.0140220 & 224 0.191/0.127 0.0075 / 0.0050 0.191/0.279 0.0090 / 0.0110 0.241/0.343 0.0095 / 0.0135

22

8 Operation

8.1 Troubleshooting guide

A properly sized and installed pump should provide trouble- free operation; however, problems in pumping systems may occurover time. The following information may help in identifying and resolving such problems:

Problem Possible cause(s) Solution(s)Drive motor not running Check circuit breakers, fusesKeys sheared or missing Replace keysDrive belts, etc. slipping or broken Adjust or replace

Pump not turning

Shaft or gears sheared ReplaceNo flow, pump turning Rotation in wrong direction Reverse rotationNo flow, pump not Inlet valve closed Open valvepriming Inlet line clogged Clean line and filters

Air leaks because of bad seals and/or pipe Replace seals, pressurize lines to check for leakageconnectionsSpeed of pump too slow Increase speed, fill inlet lines, install foot valveLiquid drains or siphons Install foot or check valvesAir lock due to fluids that may vaporize or allow Install air bleed in lines near pumpgas to come out of solutionExcess clearance between rotors, body and cover Increase pump speed, install foot valve, have pump rebuiltNet inlet pressure too low Check Net Inlet Pressure Available at Pump and Net Inlet Pressure Required by Pump.

Calculate system and modify inlet system as needed.With vacuum inlet system, atmospheric “blow back” Install check valve in discharge lineprevents pump from starting flow

No flowRelief valve not properly adjusted or held open by

foreign materialAdjust or clear valve

Fluid vaporization Filters, valves, inlet filters or lines clogged Clean(starved Pump inlet) Inlet line too small or too long, too many valves Make necessary changes

or fittings, filter too smallIncrease level in source tank or pressurize tankNet Inlet Pressure Available at Pump too lowSelect larger pump with less inlet pressure required

Viscosity of pump fluid higher than anticipated Reduce pump speed (lower flow will result) or modify systemTemperature of fluid higher than anticipated Provide cooling, reduce speed, modify system to increase available inlet pressureSpeed too low Increase speedInsufficient flowAir leaks because of bad seals and/or pipe

connectionsReplace seals, pressurize lines to check for leakage

Relief valve not Adjust/clean Openadjusted or held Flow diverted in system Check system valves and controls

Hot clearance rotors used with “cold” or low Replace with standard rotorsviscosity fluidWorn pump Increase speed, recondition pumpPressure too high Modify systemCavitation due to high fluid Viscosity, high Reduce speed and/or temperature, modify systemvapor pressure or high temperatureInlet Pressure Available less than Inlet Modify SystemPress RequiredAir or gas in system due to system leaks Fix leaksDissolved gas or naturally aerated products Reduce discharge pressure, reduce speed and/or temperature, modify system

Check back face and rotor to cover clearances and reshim as necessaryCheck for distortion of pump due to Installation of piping.

Rotor to body contact

Reassemble pump and/or re-install pipingPressure higher than pump is Rated Reduce pressureWorn bearings or gears Replace as needed, ensure regular lubricationRotor to rotor contact noise due to twisted shaft, Rebuild with new parts as neededsheared keys, loose or mistimed gears, worn splinesRelief valve chattering Readjust, repair or replace valve

Noisy operation

Drain train components Lubricate, repair or replace as neededPump overheats, Higher viscous losses than anticipated If pump is within rating, increase drive sizestalls, draws Pressure higher than anticipated Reduce speed, increase line sizeexcessive Fluid colder than anticipated, high viscosity Heat fluid/insulate and heat lines, increase running clearancescurrent Fluid sets up during shutdown Insulate or heat lines, install recirculating or “soft start” drive, flush with different fluid(trips breaker, Fluids such as chocolate, latex build up on Increase running clearancesblows fuses) internal pump surfacesPump service life not Misalignment of drive and piping, Align piping and drive

excessive pump overhangas long as expected Abrasive fluid Use larger pump at slower speed

Bearings and gears lack lubrication Establish and follow lubrication scheduleSpeeds and pressures higher than pump is rated Reduce speed and pressures by system modificationPump corrodes Upgrade material used in pump

23

How to contact Alfa LavalContact details for all countries arecontinually updated on our website.Please visit www.alfalaval.com to access the information direct.

toc2.1 General description Normal operationNoise Levels

3.1 Important information 3.2 Recycling information 3.3 Safety precautions

4.1 Unpacking, Handling and Storage 4.2 Installation 4.3 System design and installation 4.4 Startup checklist

5.1 Cleaning and maintenance 5.2 Cleaning

6.1 Preventive maintenance 6.2 Annual maintenance

7.1 Pump head and seal assembly and disassembly 7.2 Gear box disassembly and assembly Gear box disassemblyGear box assemblyReference table

8.1 Troubleshooting guide

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